Pleated filtration media, media packs, filter elements, and methods for filtering fluids

Abstract

Pleated filtration media, media packs, filter elements, and methods for filtering fluid are provided which contain three dimensional flutes in the media surface, the flutes configured to improve filter performance. In certain embodiments the flutes have defined peaks that reduce masking between adjacent pleats, the flutes have ridges along their length to modify flute cross sectional geometry, and/or the flutes provide for volume asymmetry across the media.

I claim: 
     
       1. A pleated filtration media pack comprising:
 (a) filtration media having a first set of pleat folds forming a first face, a second set of pleat folds forming a second face, and wherein the filtration media extends between the first set of pleat folds and the second set of pleat folds in a back and forth arrangement such that the first and second faces are substantially parallel; 
 (b) at least a portion of the filtration media extending between the first set of pleat folds and the second set of pleat folds comprises flutes forming first flute peaks and second flute peaks,
 i) wherein the flutes extend directionally from the first set of pleat folds toward the second set of pleat folds, and 
 ii) wherein at least 25% of the flutes in the pleated filtration media pack comprise at least one ridge between adjacent flute peaks, the ridges extending along at least 25% of the flute length between the first set of pleat folds and the second set of pleat folds, wherein each ridge is a line of intersection between differently-sloped media portions; 
 
 (c) at least a portion of the flutes extending from the first set of pleat folds to the second set of pleat folds comprise a D2/D1 value of at least 1.05, wherein D2 is the media length corresponding to the flute width, and D1 is the flute width; and 
 (d) wherein the flutes exhibit width to height aspect ratio (D1/J) of at least about 2.0. 
 
     
     
       2. A pleated filtration media pack according to  claim 1 , wherein at least 25% of the flutes in the pleated filtration media pack comprise at least two ridges between adjacent flute peaks and extending along at least 25% of the flute length between the first set of pleat folds and the second set of pleat folds. 
     
     
       3. A pleated filtration media pack according to  claim 1 , wherein the filtration media has at least one cross section wherein the flutes have a media cross-sectional area asymmetry of at least 10%. 
     
     
       4. A pleated filtration media pack according to  claim 1 , wherein the flutes exhibit a D2/D1 value of at least 1.1. 
     
     
       5. A pleated filtration media pack according to  claim 1 , wherein the flutes exhibit a D2/D1 value of at least 1.2. 
     
     
       6. A pleated filtration media pack according to  claim 1 , wherein the flutes exhibit a width to height aspect ratio of at least 3.0. 
     
     
       7. A pleated filtration media pack according to  claim 1 , wherein the filtration media exhibits a media volume asymmetry of at least 10%. 
     
     
       8. A pleated filtration media pack according to  claim 1 , wherein the filtration media exhibits a media volume asymmetry of at least 50%. 
     
     
       9. A pleated filtration media pack according to  claim 1 , wherein the flutes extend at an angle of about 60 degrees to about 150 degrees relative to one of the first face or the second face. 
     
     
       10. A pleated filtration media pack comprising:
 (a) filtration media having a first set of pleat folds forming a first face, a second set of pleat folds forming a second face, and wherein the filtration media extends between the first set of pleat folds and the second set of pleat folds in a back and forth arrangement to form a plurality of pleats, the pleats having a substantially uniform depth; 
 (b) at least a portion of the filtration media extending between the first set of pleat folds and the second set of pleat folds comprises flutes forming first flute peaks and second flute peaks, wherein the flutes extend directionally from the first set of pleat folds toward the second set of pleat folds, and 
 (c) wherein the filtration media exhibits a media asymmetric volume arrangement so that a volume on one side of the media is greater than a volume on the other side of the media by at least 10%; 
 (d) at least one of the first flute peaks or the second flute peaks have a radius of less than 2 millimeters; and 
 (e) at least a portion of the flutes extending from the first set of pleat folds to the second set of pleat folds comprise a D2/D1 value of at least 1.05, wherein D1 is the flute width and D2 is the media length corresponding to the flute width. 
 
     
     
       11. A pleated filtration media pack according to  claim 10 , wherein the flutes exhibit a width to height aspect ratio of at least 2.0. 
     
     
       12. A pleated filtration media pack according to  claim 10 , wherein the flutes exhibit an open channel width height ratio of greater than 2.0. 
     
     
       13. A pleated filtration media pack according to  claim 10 , wherein at least 25% of the flutes in the pleated filtration media pack comprise at least one ridge between adjacent flute peaks that extends along at least 25% of the flute length between the first set of pleat folds and the second set of pleat folds, wherein each ridge is a line of intersection between differently-sloped media portions. 
     
     
       14. A pleated filtration media pack according to  claim 10 , wherein the flutes exhibit a width to height aspect ratio range of 4 to 8. 
     
     
       15. A pleated filtration media pack according to  claim 10 , wherein the flutes extend at an angle of about 60 degrees to about 150 degrees relative to one of the first face or the second face. 
     
     
       16. Pleated filtration media pack comprising:
 (a) filtration media having a first set of pleat folds forming a first face, a second set of pleat folds forming a second face, and wherein the filtration media extends between the first set of pleat folds and the second set of pleat folds in a back and forth arrangement such that the first and second faces are substantially parallel; 
 (b) at least a portion of the filtration media extending between the first set of pleat folds and the second set of pleat folds comprises flutes forming a first set of flute peaks and a second set of flute peaks, wherein the flutes extend directionally from the first set of pleat folds to the second set of pleat folds; 
 (c) wherein at least 25% of the flutes in the pleated filtration media pack comprise at least one ridge between adjacent flute peaks and extending along at least 25% of the flute length between the first set of pleat folds and the second set of pleat folds, wherein each ridge is a discontinuity in the curvature of the flute; and 
 (d) at least a portion of the flutes extending from the first set of pleat folds to the second set of pleat folds comprise a D2/D1 value of at least 1.05, wherein D1 is the flute width and D2 is the media length corresponding to the flute width. 
 
     
     
       17. A pleated filtration media pack according to  claim 16 , wherein at least 25% of the flutes in the pleated filtration media pack comprise at least two ridges between adjacent flute peaks and extending along at least 25% of the flute length between the first set of pleat folds and the second set of pleat folds. 
     
     
       18. A pleated filtration media pack according to  claim 16 , wherein the filtration media has at least one cross section wherein the flutes have a media cross-sectional area asymmetry of at least 10%. 
     
     
       19. A pleated filtration media pack according to  claim 16 , wherein the flutes extend at an angle of about 60 degrees to about 150 degrees relative to one of the first face or the second face. 
     
     
       20. A pleated filtration media pack according to  claim 16 , wherein the flutes exhibit a width to height aspect ratio range of 4 to 8.